Portable spa with interchangeable overlay panels

ABSTRACT

The present invention is directed to a portable spa comprising a shell having a plurality of seats and an arrangement of water jet assemblies. At least one overlay panel is removably secured to a portion of the shell by the jet assemblies, wherein the jet assemblies extend through both the overlay panel and the shell. In one embodiment, the overlay panel is secured to an upper portion of a seat. The upper portion of the seat has a receiver that is recessed from the outer surface of the seat and cooperatively dimensioned with the overlay panel. The jet assembly comprises a stem that extends through a shell opening and a panel opening. Each jet assembly includes a sealing element that engages the panel and the shell to seal the shell opening. The jet assembly also includes a securing element that provides a clamping force to secure the overlay panel against the shell. In an installed position, the overlay panel is secured against the receiver and the seat by at least one jet assembly that extends through both the panel and the shell.

CROSS-REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C §120, this application claims the benefit of U.S.Provisional Application No. 60/860,728 which was filed on Nov. 22, 2006.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

TECHNICAL FIELD

The invention relates to a portable spa featuring interchangeable andcolored overlay panels secured to the spa shell by a jet assembly. Morespecifically, the invention provides a portable spa or hot tub withoverlay panels that are removably secured to a portion of the shell,such as a seat, by the jet assembly that extends through both the shelland the panel.

BACKGROUND OF THE INVENTION

Portable spas, or hot tubs as they are also referred to, are well-knownand can be found in both residential and commercial settings. Mostportable spas include an arrangement of seats, such as recline,captain's and waterfall seats, and an array of jets, such asdirectional, deep tissue, bullet, pulsing, and oscillating jets. Whilesuch conventional portable spas provide some benefits, they neverthelesshave certain limitations. For example, the spa includes a shell that isthermoformed from an acrylic sheet, which may be colored. Once the shellis fabricated, neither the manufacturer nor the end-customer caneffectively alter the shell's color. Over time, the spa owner may becomedissatisfied with the color of the shell and the overall spa. Thus, thelong-term aesthetic appeal of conventional spas is limited.

The present invention is provided to solve the limitations ofconventional portable spas discussed above and other problems, and toprovide advantages and aspects not provided by prior portable spas. Afull discussion of the features and advantages of the present inventionis deferred to the following detailed description, which precedes withreference to the accompanying drawings.

SUMMARY OF THE INVENTION

The present invention is directed to a portable spa featuringinterchangeable and colored overlay panels secured to the spa shell by ajet assembly. More specifically, the invention provides a portable spaor hot tub with overlay panels that are removably secured to a portionof the shell by a jet assembly that extends through both the shell andthe panel. In this manner, the portable spa provides a modular approachto the attachment and removal of overlay panels. This capability enablesa spa owner or service technician to switch overlay panels as desired,thereby increasing the aesthetic appearance of the spa.

According to an aspect of the invention, an overlay panel that issecured to an upper portion of a seat by at least one jet assembly. Theupper portion of the seat includes a receiver that receives the panel ina substantially flush fit with the surrounding portions of the seat. Thepanel has a plurality of openings, wherein each opening is cooperativelypositioned with a shell opening and cooperatively dimensioned with a jetassembly to allow for its reception. In an installed position, the jetassembly extends through both the panel and the shell for securement ofthe overlay panel to the shell.

According to another aspect of the invention, the jet assembly includesa stem with a water inlet connectable to a water supply conduit, and anair inlet connectable to an air supply conduit. The stem extends throughthe overlay panel and terminates with a water outlet. An adjustabledischarge nozzle, including a bezel, allows for adjustment to thepattern and volume of water discharged from the outlet. The jet assemblyfurther includes a securing element that releasably couples the overlaypanel to the shell. The securing element comprises a locking nut and aretaining ring. To facilitate a water-tight seal amongst the overlaypanel, the shell and the jet assembly, the jet includes a gasket orseal. The gasket includes an inner lip, an outer lip, an annular channelthere between, and a projection segment extending from the inner lip. Inan installed position, the channel resides within the panel opening, theinner lip resides between the panel and the spa shell, and theprojection segment extends into the shell opening.

Other features and advantages of the invention will be apparent from thefollowing specification taken in conjunction with the followingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To understand the present invention, it will now be described by way ofexample, with reference to the accompanying drawings in which:

FIG. 1 is a perspective view of the portable spa of the invention,showing multiple seats having an overlay panel secured by jetassemblies;

FIG. 2 is a perspective view of a seat of the portable spa of FIG. 1,showing the seat having an overlay panel secured by jet assemblies;

FIG. 3 is a perspective view of seat of the portable spa of FIG. 1,showing the overlay panel exploded from the seat;

FIG. 4 is a front perspective view of a first embodiment of the overlaypanel of the invention, showing the overlay panel having a firstarrangement of openings that each receive a jet assembly;

FIG. 5 is a front perspective view of a second embodiment of the overlaypanel of the invention, showing the overlay panel having a secondarrangement of openings that each receive a jet assembly;

FIG. 6 is a front perspective view of a third embodiment of the overlaypanel of the invention, showing the overlay panel having a thirdarrangement of openings that each receive a jet assembly;

FIG. 7 is a cross-section of the portable spa of the invention, showingan installed position wherein the overlay panel is secured to a seat bya jet assembly having a securing element and a sealing element;

FIG. 8 a is a perspective view of a sealing element of the portable spaof the invention; and,

FIG. 8 b is a side view of the sealing element of the portable spa ofthe invention.

DETAILED DESCRIPTION

While this invention is susceptible of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail preferred embodiments of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiments illustrated.

FIGS. 1-7 depict a portable spa 10 including a spa shell or tub 15 in aready to use state, meaning filled with a sufficient amount of water.The shell 15 includes a number of overlay panels 20, an array of jetassemblies 25, and plurality of seats 30. Each overlay panel 20 issecured to a portion of the shell 15 by at least one jet assembly 25that extends through both the shell 15 and the panel 10. Depending uponthe configuration of the spa 10, there are different types of seats 30,including recline/recumbent, captain's and waterfall seats, and thereare a variety of jets 25, such as directional, deep tissue, bullet,pulsing, and oscillating jets. In the embodiment of FIGS. 1-7, theoverlay panels 20 are secured to an upper portion of the seat 30, whichcorresponds to the area where the spa user's torso rests against.However, the overlay panel 20 may be secured to other portions of theshell 15, including a lower portion of the seat 30, which corresponds tothe area where the spa user's legs rest against. In another embodiment,the shell 15 is configured to have an overlay panel 20 secured to boththe upper and lower portion of the seat(s) 30.

The shell 15 further includes a foot well 35 and a water filter assembly40 residing behind a protective grill 42. The shell 15 is supported by asupport frame that comprises a plurality of horizontal frame members andvertical frame members to which the various operational components thatare utilized to operate the spa 10 are coupled. These operationalcomponents generally include an ozonator, an electrical connectioninterface, a control panel, a heater assembly, and at least one pump.The control panel includes a microprocessor for operational control ofthe spa, including the components. These components reside in a cavitydefined between the support frame and the shell 15. In general terms,the pump supplies water to the jet assemblies 25 through a line orconduit and a manifold.

The spa 10 includes multiple seats 30 having an upper portion 45 and alower portion 50, wherein the upper portion 45 includes a receiver 55cooperatively dimensioned with the overlay panel 20 for its reception.Thus, the receiver 55 serves as the mounting base or interface area forthe overlay panel 20. As mentioned above, the overlay panel 20 may bemounted to other areas of the shell 15 whereby the receiver 55 may belocated in other shell areas as well (for example, the leg portion of aseat 30 can include a receiver 55). Referring to FIG. 3, the receiver 55includes an outer lip 56 a and an inner lip 56 b wherein a ridgearrangement 56 c is formed there between. As shown in FIGS. 2 and 3, thereceiver 55 is located below the removable head rest cushion 57 that canbe interchanged or swapped along with the panel 20, such that thecushion 57 and the panel 20 are color coordinated. The receiver 55includes a primary or central surface 58 (see FIG. 3) that is recessedfrom the outer surface 30 a of the seat 30. The shell 15, including theseats 30 and the receiver 55, include an array of blanks that are portedduring the manufacturing process to create a shell opening 17 forinsertion of the jet assembly 25. Accordingly, an arrangement ofopenings 17 reside within the receiver 55, while another arrangement ofopenings 17 are located in other portions of the shell 15 and seat 30,external to the receiver 55.

FIGS. 1, 2 and 7 show the overlay panel 20 in an installed position P₁,wherein the jet assemblies 25 secure the panel 20 to the seat 30. Eachjet 25 extends through both the panel 20 and the shell 15 in theinstalled position P₁. The panel 20 has a plurality of openings 22,wherein each opening 22 is cooperatively positioned with a shell opening17 and cooperatively dimensioned with the jet 25 to allow for itsreception. Referring to FIGS. 2-6, the panel 20 has various sizedopenings 22 that define an arrangement of opening 22 to accommodate thedifferent sized jets 25. For example, the openings 22 can be from 2-5inches in diameter, and different sized openings 22 can be in the samepanel 20 (as shown in the Figures). The panel 20 includes a recessedflange 23 around the opening 22 to aid with the insertion and/orpositioning of the jet assembly 25. Further, the panel 20 has aperipheral lip 24 along its periphery. Although the panel 20 is shownwith a width that tapers from top to bottom, the dimensions of the panel20 may vary. However, because the panel 20 is joined to the shell 15,the panel 20 preferably has a configuration that is consistent with theconfiguration of the receiver 55. The overlay panel 20 is substantiallyflush with the seat surface 30 a, such that there are no intrusive seamsor ridges which may diminish the enjoyment and comfort of the spa 10.The overlay panel 20 may be formed from the same material, such asacrylic, used to form the shell 15.

As shown in FIG. 7, the jet assembly 25 includes a main body portion orstem 65 with a water inlet 70 connectable to a water supply conduit 71,and an air inlet 75 connectable to an air supply conduit 76. Althoughshown as having a generally “L-shaped” configuration, the stem 65 canhave a linear configuration. The stem 65 extends through the overlaypanel 20 and terminates with a water outlet 80. An adjustable dischargenozzle 85 and a bezel 87 allow for adjustment to the pattern and volumeof water discharged from the outlet 80. Thus, the stem 65 defines aninternal passageway for the flow of air-injected water. The jet assembly25 further includes a securing element 85 that helps to releasablycouples the overlay panel 20 to the shell 15. Preferably, the securingelement 85 resides behind the shell 15 and the panel 20 and within thecavity to provide a clamping force to the panel 20 against the shell 15.In one embodiment, the securing element 85 comprises a locking nut 90and a retaining ring or washer 95. In another embodiment, the ring 95 isomitted and the nut 90 engages an inner surface of the shell 15. Priorto the outlet 80, the stem 65 includes a flange 92 with an increaseddiameter. Preferably, the flange 92 includes external threads thatengage internal threads of the nut 90. To facilitate a water-tight sealamongst the overlay panel 20, the shell 15 and the jet assembly 25, thejet 25 includes a sealing element, such as an elastomeric gasket 100(see FIGS. 7-8 a, b). As explained below, the gasket 100 is positionedbetween the panel 30, the shell 15 and the jet assembly 25 to seal theshell opening 17. Referring to FIGS. 7-8 a, b, the gasket 100 includesan inner lip 105, an outer lip 110, an annular channel 115 therebetween, and a projection segment or finger 117 extending from the outerlip 110. The projection segment 177 extends transversely, preferablysubstantially perpendicular, from the outer lip 110. Alternatively, theprojection 117 is omitted from the gasket 100.

FIGS. 1, 2 and 7 shows the spa 10 in an installed position P₁, whereinthe panel 20 is secured against the receiver 55 and the shell 10, namelythe seat 30, by at least one jet assembly 25 that extends there through.Specifically, an outer surface 20 a of the panel 20 faces toward towardsan inner surface 55 a of the receiver 55 and is secured in the aninstalled position P₁ by at least one jet assembly 25. Referring to FIG.7 and working left to right, the outlet flange 120 of the jet assembly25 is located left of the panel 20 wherein the flange 120 and the panel20 reside within the shell 15. The inner lip 105 of the gasket 100resides between the flange 120 and the inner surface 20 b of the panel20. The channel 115 resides within the panel opening 22 to receive orengage the panel 20. The outer lip 110 resides between the outer surface20 a of the panel 20 and the shell 15. Specifically, the outer lip 110is “sandwiched” between the outer panel surface 20 a and an innersurface 55 a of the receiver 55 of the shell 15. The projection orfinger 117 extends into the shell opening 17, wherein it is positionedbetween an edge of the shell 15 and the flange 92 of the stem 65. Inanother embodiment, the projecting finger 117 is omitted and the outerlip 110 resides between the inner panel surface 20 b and the outer shellsurface 15 a. The nut 90 resides against an outer surface 15 b of theshell 15 and adjacent the flange 92 to provide a clamping force, whereinthe force stabilizes the jet assembly 25 against the shell 15 andthereby secures the panel 20 against the receiver 55. The clamping forcegenerally results from the interaction of the nut 90, the shell 15, thepanel 20, the sealing element 100 and the jet assembly 25, namely theflange 120. In the configuration where the securing element 85 includesring or washer 95, the ring 95 is positioned between the nut 90 and theshell 15. In the installed position P₁, the interaction of thesecomponents—namely, the panel 20, the gasket 100 and the nut 90—helps toprevent water leaks through the spa opening 17 during operation of thespa 10.

Once the installed position P₁ is attained, the water supply line 71 canbe joined to the water inlet 70 and the air supply line 76 can be joinedto the air inlet 75. Because the nut 90 (and the ring 95) can beloosened and removed, the jet assembly 25 can be unsecured and removedfrom the spa opening 17 which allows for the removal of an existingpanel 20 and the replacement by a second panel 20. For example, a spaowner or service technician may remove a first colored panel 20, such asblue panel, and secure a second colored panel 20, such as a black panel,to a silver colored shell 15, whereby the spa 10 now has a silver andblack color configuration. Therefore, the jet assemblies 25 providemultiple functions to the spa 10—the traditional supply of water to theshell 15 and the removable securement of the overlay panel 20 to theshell 15.

While the specific embodiments have been illustrated and described,numerous modifications come to mind without significantly departing fromthe spirit of the invention, and the scope of protection is only limitedby the scope of the accompanying Claims.

1. A portable spa comprising: a shell having a plurality of seats; and,at least one overlay panel removably secured to a portion of the shellby at least one water jet assembly, wherein the water jet assemblyextends through both the overlay panel and the shell.
 2. The portablespa of claim 1, wherein the overlay panel is secured to an upper portionof a seat.
 3. The portable spa of claim 2, wherein the upper portion ofthe seat has a receiver that is both recessed from the outer surface ofthe seat and cooperatively dimensioned with the overlay panel.
 4. Theportable spa of claim 1, wherein the jet assembly includes a securingelement that provides a clamping force against the shell to secure theoverlay panel in an installed position.
 5. The portable spa of claim 4,wherein the jet assembly comprises a stem that extends through a shellopening and a panel opening.
 6. The portable spa of claim 5, wherein thestem includes a water inlet, an air inlet and an outlet, and wherein theinlets collectively form an internal passageway to the outlet.
 7. Theportable spa of claim 1, wherein the jet assembly includes a sealingelement and a securing element that engages the shell to secure theoverlay panel in an installed position.
 8. The portable spa of claim 7,wherein the sealing element comprises an inner lip, an outer lip, and achannel positioned between the inner and outer lips.
 9. The portable spaof claim 8, wherein in the installed position, the inner lip residesbetween a flange of the jet assembly and the panel, and the outer lipresides between the overlay panel and the shell.
 10. The portable spa ofclaim 8, wherein in the installed position, the channel resides within apanel opening to receive the panel.
 11. The portable spa of claim 8,wherein the sealing element further comprises a projection that extendsfrom the outer lip, the projection being received within a shell openingin the installed position.
 12. A portable spa comprising: a shell havinga plurality of seats and a plurality of water jet assemblies; at leastone overlay panel; and, wherein in an installed position, at least onewater jet assembly extends through both the overlay panel and the shellto removably secure the panel to the shell.
 13. The portable spa ofclaim 12, wherein the overlay panel is secured to a recessed receiver ofa seat, wherein the receiver is cooperatively dimensioned with theoverlay panel.
 14. The portable spa of claim 12, further comprising asecuring element that provides a clamping force against the shell tosecure the overlay panel in the installed position.
 15. The portable spaof claim 12, further comprising a sealing element including an innerlip, an outer lip, and a channel positioned between the inner and outerlips.
 16. The portable spa of claim 15, wherein in the installedposition: the inner lip resides between a flange of the jet assembly andthe panel; the channel resides within a panel opening to receive thepanel; and, the outer lip resides between the overlay panel and theshell.
 17. The portable spa of claim 16, wherein the sealing elementfurther includes a projection that extends from the outer lip, theprojection being received within a shell opening in the installedposition.
 18. A portable spa comprising: a shell having a plurality ofseats and an arrangement of water jet assemblies; an overlay panel; asecuring element; and, wherein in an installed position, at least onewater jet assembly extends through both the overlay panel and the shellfor engagement with the securing element to removably secure the panelto the shell.
 19. The portable spa of claim 18, wherein the overlaypanel is secured to a recessed receiver of a seat, wherein the receiveris cooperatively dimensioned with the overlay panel.
 20. The portablespa of claim C1, wherein the securing element comprises a nut thatengages an outer surface of the shell in the installed position.
 21. Theportable spa of claim 20, further comprising a sealing element includingan inner lip, an outer lip, and a channel positioned between the innerand outer lips.
 22. The portable spa of claim 21, wherein in theinstalled position: the inner lip resides between a flange of the jetassembly and the panel; the channel resides within a panel opening toreceive the panel; and, the outer lip resides between the overlay paneland the shell.
 23. The portable spa of claim 22, wherein the sealingelement further includes a projection that extends from the outer lip,the projection being received within a shell opening in the installedposition.